Crimping apparatus

ABSTRACT

An automatic crimping apparatus is provided for applying electrical terminals on the end of a wire inserted in a crimp station comprising a crimp anvil mounted on a base, a crimp arm for mounting crimp tooling operatively connected to the base through a toggle linkage, a feed mechanism for supplying terminals to the crimping station in the form of a continuous strip, and a pneumatic control system wherein a four-way airpilot valve and first and second pressure-relief valves are used to sequence the drive mechanism for the crimp arm and feed mechanism.

United States Patent 1191 Keim et al.

[ Jan. 14, 1975 CRIMPING APPARATUS 2,858,537 11/1958 Cootes 72/451 xInventors: Kenneth J Keim Lewisberry; 3,064,706 11/1962 Ehmann 72/451 XDirk Landman, Mechanicsburg, both of Przmary Exammer-Thomas H. Eager[73] Assignee: E. 1. du Pont de Nemours and Company, Wilmington, Del.[57] ABSTRACT [22] Filed: Jam 14, 1974 An automatic crimping apparatusis provided for applying electrical terminals on the end of a wire in-[21] Appl- Ive-14331377 serted in a crimp station comprising a crimpanvil mounted on a base, a crimp arm for mounting crimp 5 CL 29/203 DT,29/203 DS, 72/451 tooling operatively connected to the base through a 51Int. Cl Hlr 43/04, B21 j 9/18 toggle linkage, a feed mechanism forSupplying termi 5 Field f Search 29/203 DT 203 D303 R, nals to thecrimping station in the form of a continu- 29/203 72/451 ous strip, anda pneumatic control system wherein a four-way air-pilot valve and firstand second pressure- 5 References Cited relief valves are used tosequence the drive mecha- UNITED STATES PATENTS nism for the crimp armand feed mechanism.

2,712,253 7/1955 Kontra, Sr. 81/367 X 10 Claims, 4 Drawing Figures I l 1ll 1 56 Q 1 11 5a 54 7 324 222 220 e I V 1 J' |9| 1 1 3 ,2: 7 as 'i;/;/1 I60 52 l F Q9 1 l l '92 e a l Q 182 l 1 132 $32 32 A34 98 36 'j ;:i W52 x I "139 ll; 29

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PILOT RH. Relief Hole BACKGROUND OF THE INVENTION 1. Field of theInvention The invention relates to an apparatus for applying terminalsto wire ends, and particularly relates to an apparatus for feedingterminals in a continuous strip to a crimping station and crimping theterminals on the ends of wires. More particularly, the invention relatesto an apparatus having a pneumatically driven crimping arm and feedmechanism, and still more particularly the invention relates to anapparatus having a pneumatic control system for sequencing the operationof the crimp arm and feed mechanism for supplying terminals in the formof a continuous strip to the crimping station.

2. Description of the Prior Art Automatic terminal-applying apparatusare well known for crimping electrical terminals or connectors to theends of wires. Generally, these automatic apparatus have employed areciprocally driven ram, as described in U.S. Pat. No. 2,858,537, forengaging crimp tooling with the electrical terminals which arepositioned in the form of a continuous strip on a crimp anvil, and amechanical linkage to the reciprocating ram to sequence the crimpingaction of the ram and feeding of the terminals to the crimp station.Another press apparatus wherein a pair of elongated arms are pivotedimmediate their ends to swage sleeves on a wire rope is described inU.S. Pat. No. 3,064,706. A forming tool wherein one jaw or arm member ispivoted with respect ,to another jaw or arm member by a toggle linkageconnected to the jaws is described in U.S. Pat. No. 2,712,253.

The apparatus of the present invention providesfor automaticallyapplying an electrical terminal to the end of a wire and for sequencingthe feeding of terminals in the form of a continuous strip to a crimpingstation and the crimping of the terminals on ends of wires. Independentfeeding and crimping drive mechanisms provide for smooth and accuratefeed of the terminals in the form of a continuous strip to the crimpingstation and for positive crimping of the terminals on the end of a wireinserted in the crimping station. Additionally, the present inventionprovides an apparatus which is economically constructed yet rugged andextremely efficient in terms of crimping forces exerted and speed.

SUMMARY OF THE INVENTION According to the present invention, anapparatus is provided for applying a terminal to the end-of a wirecomprising:

crimp means connected to the base and a toolmounting block disposedthereon,

a crimp arm having one end pivotally connected to the base and atool-mounting block on the other end of the arm,

first drive means connected to the crimp arm for crimping the terminalon the wire in the crimping station,

a feed track for supplying the terminals to the crimping station,

means for feeding the terminals along the feed track to the crimpingstation,

second drive means connected to the means for feeding the terminals, and

pneumatic control means for sequentially actuating the first drive meansand the second drive means and simultaneously deactivating the first andsecond drive means.

In a preferred embodiment of the apparatus of the invention, the firstand second drive means comprise air cylinders, and the control meanscomprises a fourway air-pilot valve and first and second pressure-reliefvalves for sequentially actuating or extending the air cylinders andsimultaneously deactuating or retracting the air cylinders.Additionally, in the preferred embodiment of the apparatus, the free endof the toggle links is connected to the base on an eccentric shaft foradjusting the travel of the crimp arm and the height of the crimp inapplying the terminals to the end of a wire.

. Further, in a preferred embodiment of the apparatus,

the toggle linkage is over-driven, momentarily releasing the forceapplied to a crimp barrel on the terminal and. on the return stroke ofthe toggle linkage, reapplying the crimp force to the crimp barrel onthe terminal, thus insuring uniform height of the crimp barrel on theterminal by double-crimping.

The present invention provides for automatically applying electricalterminals on the ends of wires at high production rates and exerts acrimp force equal to or greater than crimping apparatus using areciprocating ram. Additionally, the apparatus of the present inventionprovides for accurately and positively positioning the electricalterminals at the crimping station and positive clearance of the crimptooling from the crimping station before feeding a new terminal to thecrimping station.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side elevation of apreferred embodiment of the apparatus of the invention.

FIG. 1A is a detailed view illustrating electrical terminals in the formof a continuous strip for use in the apparatus of the invention.

FIG. 2 is a front elevation of the embodiment of the invention of FIG.1.

FIG. 3 is a schematic diagram of a control system of the preferredembodiment of the apparatus of the invention.

DETAILED DESCRIPTION OF THE INVENTION A referred embodiment of anapparatus of the invention is described below with reference to theattached drawings wherein the same numerals are used throughout toidentify the same element.

A base 10 having side members 12 with mounting flanges l4, uprightsections 16 and a cross member 18 is provided for mounting the variouscomponent elements of the apparatusof the invention. A terminal supplyreel bracket 20 is mounted on one side of the upright section 16 of oneof the side members 12 of base 10. A shaft 22 is mounted on bracket 20for loading a reel 25 of terminals 26 in the form of a continuous strip27. A drag spring 28 is provided on bracket 20 for engaging aside flangeon reel 25. A guide member 24 is mounted on bracket 20 for guiding theterminals to a feed-track assembly 29.

A crimp arm 30 having a yoke 32 at one end with shaft ways 34 ispivotally mounted on shaft 36 disposed in shaft ways 38 in uprightsection 16 of side members 12 of the base 10. Shaft 36 is secured bycollars 40. A tool block 42 is provided on the free end of crimp arm 30for mounting the crimp tooling. A shaft way 44 is machined in tool block42 for receiving a shaft 46. Shaft 46 is connected to the free end oflinks 48 of toggle linkage 50. Links 52 of toggle linkage 50 connects atone end to a drive eye 54 of toggle linkage 50 and links 48 by pivotshaft 56 of the toggle linkage 50. Collars 58 are provided on the ends'of the shaft 56. Eye link 54 of the toggle linkage 50 is connected topiston rod 60 of crimp-drive air cylinder 62. A jam nut 64 is threadedon piston rod 60 for adjusting and locking the length of the drivestroke of toggle linkage 50. Air cylinder 62 is pivotally mountedbetween upright section 16 of side members 12 of the base 10, withtrunnion mounting pin 66 and cap screw 68. The end of links 52 of thetoggle linkage 50 connects to shaft 72 journaled in shaft ways 76 inside members 12 of the base 10. Shaft 72 has two eccentric sections 74which are received in the shaft ways 76. Saw cuts 84 are provided fromthe bottom of side members 12 to shaft ways 76, and cap screws 86 arethread-mounted spanning the saw cuts 84 for locking the eccentricsections 74 of shaft 72 in shaftways 76. Collar 80, having lever 82 foradjusting eccentric sections 74 of shaft 72 and collar 78 are mounted onthe ends of shaft 72.

Feed-track member 90 having a grooved feed track 92 for supplying theterminals 26 in the form of a continuous strip to the crimping stationis fixedly mounted between side member 12 of base 10. A drag plate 94 isspring-mounted on member 90 by shoulder screws 96 and springs 98.

A feed arm 100 is pivotally mounted on pivot pin 102, which is fixedlymounted on member 90. A spring 104 is connected between a pin 106 onmember 90 and pin 108 on feed arm 100 over the center of pivot pin 102.An actuator pin 110 is fixedly mounted at one end of member 100 forengaging in slot' 112 of block 114 thread-mounted on piston rod 116 offeed drive air cylinder 118.'A jam nut 122 is thread-mounted on pistonrod 116 for adjusting and locking the position of block 114. Aircylinder 118 is mounted with trunnion mounting pins 120 and cap screws121 in brackets 123 on the underside of member 90. A feed finger 130 ispivotally mounted on the pivot pin 132 in feed arm 100. A torsion spring134 is mounted on pin 132 to bias the feed finger in track 92 of member90 for engaging the terminals 26 of the terminal strip 27. A stop screw137 is thread-mounted in feed arm 100 and adjustably positioned andlocked by jam nut 139. Stop member 136 is mounted on member 90 forengaging stop screw 137 and halting the forward travel of feed arm 100.Stop member 136 may be adjustably mounted to provide fordifferent-length feedstrokes for different-length terminals. Similarly,stop member 135, stop screw 138 and jam nut 131 halt the rearward travelof feed arm 100.

Conventional tooling for crimping terminals having an insulation crimpbarrel and a wire crimp barrel is mounted on the tool block 42 of crimparm 30 and cross member 18 of base 10. Suitable upper tooling is mountedin tool block 42 with adapter 180 and includes a wire insulation barrelcrimp tool 182 and wedge member 184 mounted in slot 185 for adjustingthe height of the crimp of the insulation barrel on the terminal. A wirepositioner and terminal ejector 186 is slideably mounted between theinsulation barrel crimp tool 182 and a wire barrel crimp tool 192. Aspringloaded pin 189 is mounted in the tool block 42 for engaging wirepositioner and ejector 186. Spring 190 is mounted on the pin 189 in thetool block 42. Pin cap 191 is mounted on the end of pin 189 at the topof the tool block 42. Upper cutoff tool 194 is mounted between the wirebarrel crimp tool 192 and spacer 196 in the tooling block 42. The lowertooling mounted on I cross member 18 comprises an anvil holder 200 formounting the crimp anvil 202 and anvil retainer 204. A wire stop member206 is pivotally mounted on member 208, which is mounted on anvil holder200. Spaced lower, front and rear cutoff plates 210 and 212 are mountedon member behind anvil 202. A recess slot 214 is formed between thespaced plates 210 and 212. An ejector contact element 220 is mounted onmember 222, which is fixedly mounted'to ejector mount frame 224. Frame224 is fixedly mounted on side members 12 of the base 10.

With particular reference to FIG. 3, a regulated air source 140 isprovided for supplying air to the control system of the apparatus of theinvention. Air is supplied by line 142 to a foot-actuated valve 144,which is connected to air-pilot port -4 of four-way air-pilot valve 150by line 146 and to input port 150-1 of valve 150 by line 148. Outputport 150-2 of valve 150 is connected to the forward ends of aircylinders 62 and 118 through air line 152 and branch air line 154. Airline 158 connects output 150-3 of valve 150 to pressurerelief valve 162and to the rear end of air cylinder 62 through branch air line 160. Therelief port of valve 162 is connected to relief valve 166 by air line164 and to the rear end of air cylinder 118 by branch air line 168. Therelief port of valve 166 is connected to air pilot 150-5 of valve 150 byair line 172. Flow-control valves 156 are provided in branch air lines154 and 168 to the forward and rear ends of air cylinder 118. Relief pinholes 174 are provided in air lines 164 and 172 and mufflers 176 areprovided in discharge ports 150-6 and 150-7 of valve 150.

The operation of the apparatus of the invention may be readilyunderstood with reference to the drawings and description below.

Electrical terminals 26 having a terminal on one end and an insulationcrimp barrel and wire crimp barrel on the other end in the form of acontinuous strip with a blank section connecting adjacent terminals areillus trated in detailed drawing 1A. The continuous strip 27 is fed fromreel 25 around guide 24 to groove 92 in the feed track member 90. Dragplate 94 is manually pivoted upwards to thread the strip 27 under feedfinger 130 and position a terminal 26 on a crimp anvil 202 at thecrimping station. Drag plate 94 is released and the crimping station isready to receive a wire with the insulation stripped from the endthereof. The wire end is manually inserted through the open insulationand wire crimp barrels of the terminal 26 until the wire end engageswire stop 206, which is positioned above the terminal 26. Foot switchvalve 144 is actuated by an operator and air supplied to air-pilot 150-4switches valve 150 to provide air from output port 150-3 to the rearend'of crimp drive air cylinder 62. Air cylinder 62 is extended, andpiston rod 60 drives toggle linkage 50. Tool block 42 of crimp arm 30 isdriven arcuately downward to engage the upper tooling with the terminalpositioned on crimp anvil 202. The fork-shaped wire positioner 186positions the wire in the center of the crimp barrels on the terminaland the insulation crimp tool 182 and wire crimp tool 192, respectively,crimp the insulation and wire crimp barrels of the terminal on the endof the wire. Upper cutoff tool 194 engages the blank portion of thestrip 27 between lower front and rear cutoff plates 210 and 212. Theblankedout section of the strip falls in slot 214. Toggle linkage 48 isoverdriven, i.e., the tooling is driven beyond top dead center so as toinsure total crimp stroke is applied to the crimp barrels before aircylinder 62 is fully extended. When air cylinder 62 is fully extended,he crimp force is relieved on the crmp barrels, but the terminal isstill securely held between the crimp tooling and the crimp anvil 202.When the crimp drive air cylinder 118 is fully extended, the firstpressure-relief valve 162 opens, and air is supplied to rear end offeeddrive air cylinder 118 through one of the flow-control valves 156.The flow-control valve 156 regulates the rate at which cylinder 118 isextended. Block 114 having slot 112 mounted on piston rod 116 of aircylinder 118 starts forward. Slot 112 delays engagement of actuator pin110 on feed member 100 and retraction of the feed finger 130. When slot114 engages actuator pin 110, the feed arm 100 and feed finger 130 areretracted. Spring 104 over the center of pivot pin 102 shifts to abovethe center of the pivot and holds feed arm 100 and feed finger 130 inthe fully retracted position. When feed-drive air cylinder 118 is fullyextended, pressure-relief valve 166 opens, and air line 172 supplies airto air pilot 150-5 of valve 150 and switches the air supply to outputport 150-2. Air is supplied from port 150-2 to the front end of the aircylinders 62 and 118, and the pistons are retracted. Piston rod 60connected to toggle linkage 50 is retracted, and the crimp tooling whichwas over-driven repeats the crimp action on the crimp barrels of theterminal 26, thus double-crimping the terminals to insure uniform crimpheight and minimize any resilient expansion of the initial crimp. Thetoggle linkage 48 pivots the crimp arm 30, lifting the tool block 42 andcrimp tooling mounted therein from the crimping station and clearing thecrimping station for feeding of anoter terminal 26 of the terminal strip27.

Terminal 26 having the wire end crimped therein is lifted by thecrimp'tooling with tooling block 42 on crimp arm until pin cap 191engages ejector stop 220 and pin 189 drives wire positioner and ejector186 down to eject the crimped terminal from insulation and wire crimptools 182 and 192. The wire stop member 206 pivots upward as the crimpedterminal is lifted from the anvil, and then it falls to its normalposition when the crimped terminal is ejected from the crimping station.

Piston rod 116 of air cylinder 118 is retracted, and slot 112 in block114 delays engagement of the actuator pin 110 on feed arm 100 until thecrimp tooling has cleared the crimping station. Feed arm 100 drives thefeed finger 130 forward when actuator pin 110 is engaged by the front ofslot 112 in block 114. The feed finger 130 is spring-biased inengagement with the terminals 26 in the continuous strip 27 by spring134 on pivot pin 132. The feed finger 130 advances the strip 27 until anew terminal 26 is accurately positioned on the crimp anvil 202 underthe wire stop 206 at the crimping station. Stop screw 137 is preciselyadjusted and locked by jarn nut 139 to accurately control the feedstroke of feed arm 100 so that the feed finger 130 accurately positionsthe terminals 26 on the crimp anvil 202 at the crimp station. Spring 104is shifted below the center of pivot pin 102 when the feed arm 100 isadvanced. Air cylinder 118 holds the feed arm forward and the feedfinger securely holds the continuous strip 27 of terminals 26 in thefeed track groove 92 and the new terminal on crimp anvil 202 at thecrimping station.

With a new terminal 26 properly positioned on the crimp anvil 202, theapparatus is ready for receiving and crimping another wire in theterminal. On actuation of foot valve 144, the crimp and feed cycles,described above, are repeated to crimp another terminal on a wireinserted in the crimping station and position a new terminal 26 on thecrimp anvil 202.

The apparatus of the invention can be readily adapted for applyingvarious sizes and shaped electrical terminals having one or more crimpbarrels to wires by changing the crimp tooling. The height of the crimpbarrels on the wires may be readily and simply adjusted by releasing thecap screws 86 and rotating the eccentric sections 74 of shaft 72 withlever 82 and collar 80 on one side of the apparatus.

While the above description and attached drawings illustrate a preferredembodiment of the apparatus of the invention, it is apparent that theother embodiments and modifications are equivalent and will be obviousto one skilled in the art; therefore, the invention is not to be limitedexcept by the appended claims.

What is claimed is:

1. An apparatus for applying terminals to the ends of wires comprising,

a base having a crimping station for receiving a terminal and a wire,

crimp means connected to said base and a tool mounting block disposedthereon,

first drive means connected to said crimp arm for crimping said terminalon said wire,

feed means for supplying terminals to said crimping station,

second drive means connected to said feed means,

and

control means for sequentially activating said first and second drivemeans and simultaneously deactivating said first and second drive means.

2. An apparatus, as recited in claim 1, wherein said first drive meansadditionally comprises a toggle linkage and at least one of the togglelinks is connected to an eccentric shaft for adjusting the stroke of thecrimp arm.

3. An apparatus, as recited in claim 1, wherein said control meanscomprises a four-way air pilot valve and a pair of pressure reliefvalves, and said pressure relief valves are connected in series to anoutlet port of said four-way air pilot valve and a relief port of one ofsaid pressure relief valves is connected to an air pilot port of saidfour-way air pilot valve.

4. An apparatus, as recited in claim 1, wherein said feed meanscomprises a member having an actuator pin, and said second drive meanscomprises a drive member having a slot disposed therein for delayingengagement of said actuator pin by said drive means.

5. An apparatus for applying terminals on the ends of wires comprising,

a base having lower crimp tooling mounted thereon at a crimping stationfor receiving a terminal and an end of a wire,

a crimp arm having one end pivotally connected to said base and a toolblock for mounting upper crimp tooling on the other end of said crimparm,

a toggle linkage having a first link connected to said tool block on oneend of said crimp arm and a second link connected to said base firstpneumatic drive means connected to said toggle linkage for engaging saidupper crimp tooling mounted on said crim arm with said lower tooling onsaid base and crimping the terminal on the end of the wire at saidcrimping station,

a feed track for supplying said terminals to said crimping station,

means for feeding said terminals along said feed track to said crimpingstation,

second pneumatic drive means for engaging said means for feedingterminals, and

pneumatic control means for sequentially activating the first and seconddrive means and simultaneously deactivating said first and second drivemeans.

6. An apparatus, as described in claim 5, wherein said toggle linkage isconnected to said base through an eccentric shaft for adjusting theengagement of the upper and lower crimp tooling.

7. An apparatus, as recited in claim 5, wherein said control meanscomprises first and second pressure relief valves and the input port ofsaid first relief valve is connected to said first drive means and therelief port of said first relief valve is connected to the input port ofsaid second pressure relief valve and to said second drive means.

8. An apparatus, as recited in claim 7, wherein said control meansadditionally comprises a four-way air pilot valve and the relief port ofsaid second relief valve is connected to an air pilot port of said pilotvalve.

9. An apparatus, as recited in claim 5, wherein said means for feedingsaid terminals comprises a feed arm pivotally mounted on said feed trackhaving a feed finger mounted on one end and a spring connected from saidbase to said feed arm over the center of the pivot point of said feedarm, and the other end of the feed arm is connected to said second drivemeans.

10. An apparatus, as recited in claim 9, wherein said second drive meanscomprises a drive member having a slot disposed therein for delayingengagement of said actuator pin on said feed arm.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION PAHN'I N0 v j0,708 0mm Jamar'y 1 1, 1976 amine 1 f-ieztnet11 John Veirn and DirkLandman Jifffifil 'lhai exror appears m the above-wdentified patent andthat said Letters Pater 1a erz as shown beiuw Column 6, line 3U, "armshould read --rrieans--.

.ii fignecl and sealed this 17th day of June 1975.

Attest:

C. IIARSHALL DAN? Commissioner of Patents Attestin Ii -f. Lice-r andTrademarks

1. An apparatus for applying terminals to the ends of wires comprising,a base having a crimping station for receiving a terminal and a wire,crimp means connected to said base and a tool mounting block disposedthereon, first drive means connected to said crimp arm for crimping saidterminal on said wire, feed means for supplying terminals to saidcrimping station, second drive means connected to said feed means, andcontrol means for sequentially activating said first and second drivemeans and simultaneously deactivating said first and second drive means.2. An apparatus, as recited in claim 1, wherein said first drive meansadditionally comprIses a toggle linkage and at least one of the togglelinks is connected to an eccentric shaft for adjusting the stroke of thecrimp arm.
 3. An apparatus, as recited in claim 1, wherein said controlmeans comprises a four-way air pilot valve and a pair of pressure reliefvalves, and said pressure relief valves are connected in series to anoutlet port of said four-way air pilot valve and a relief port of one ofsaid pressure relief valves is connected to an air pilot port of saidfour-way air pilot valve.
 4. An apparatus, as recited in claim 1,wherein said feed means comprises a member having an actuator pin, andsaid second drive means comprises a drive member having a slot disposedtherein for delaying engagement of said actuator pin by said drivemeans.
 5. An apparatus for applying terminals on the ends of wirescomprising, a base having lower crimp tooling mounted thereon at acrimping station for receiving a terminal and an end of a wire, a crimparm having one end pivotally connected to said base and a tool block formounting upper crimp tooling on the other end of said crimp arm, atoggle linkage having a first link connected to said tool block on oneend of said crimp arm and a second link connected to said base, firstpneumatic drive means connected to said toggle linkage for engaging saidupper crimp tooling mounted on said crim arm with said lower tooling onsaid base and crimping the terminal on the end of the wire at saidcrimping station, a feed track for supplying said terminals to saidcrimping station, means for feeding said terminals along said feed trackto said crimping station, second pneumatic drive means for engaging saidmeans for feeding terminals, and pneumatic control means forsequentially activating the first and second drive means andsimultaneously deactivating said first and second drive means.
 6. Anapparatus, as described in claim 5, wherein said toggle linkage isconnected to said base through an eccentric shaft for adjusting theengagement of the upper and lower crimp tooling.
 7. An apparatus, asrecited in claim 5, wherein said control means comprises first andsecond pressure relief valves and the input port of said first reliefvalve is connected to said first drive means and the relief port of saidfirst relief valve is connected to the input port of said secondpressure relief valve and to said second drive means.
 8. An apparatus,as recited in claim 7, wherein said control means additionally comprisesa four-way air pilot valve and the relief port of said second reliefvalve is connected to an air pilot port of said pilot valve.
 9. Anapparatus, as recited in claim 5, wherein said means for feeding saidterminals comprises a feed arm pivotally mounted on said feed trackhaving a feed finger mounted on one end and a spring connected from saidbase to said feed arm over the center of the pivot point of said feedarm, and the other end of the feed arm is connected to said second drivemeans.
 10. An apparatus, as recited in claim 9, wherein said seconddrive means comprises a drive member having a slot disposed therein fordelaying engagement of said actuator pin on said feed arm.